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~

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AVMAX 11~ VIPRD"' · - q,., NON-ROUTINE WORK CARD -~ ~ Date: Serial Nu. S.O.W. Code Trade - A1A WorK urdcr # \V9o5o 7.oftf i,) s 55L/ tJ~~ S/m SL( 8bZSS" Reference Ta.<k/Wnrk Ca7 . E~timatcd Hrs & Customer Approval Budg~i HN & Cm,loincr App:-ov:tl

~ 4Z0t L/o2s ~ ;t; _() tit,vv' u~ - _..n,,... Discrepancy/Requ ired Action: .

GcncrJICd lly /\l -~ (. 6511 CR~ ~DOrJ~ atJ ~2~llE' M Tl1t' -R,JO AUT_)3o~

~

C~W(,Q_ b ~ -r\Ai.==- ~:,~EN \M'6-, f=uL THE fVJD MU.n ~oot..

Parts Requisition

111f<-tb.5 C} JJ-IY I I I I Numbers:

Recommended Action: tvc4'. Planned Bv:J I ~ t-1,lll~e~ S'(,'=,t

RII Required'! N,..., \Vntc Yes or Nu;

Comi"""''f ~l) -~I.{- fi7 '1 Numbers·'l1 I r;,ss3!t t="Hu(="-'.l, 1:·1E IH· S

0 ~T& O~- l'W5-9'f ,J

Rectification: /l f t:),4. J .a_ t:! d -i::i.. ') r, · -.--!) /ldJ,,., II,-> AT Th,; ;::,u /) A,~, Ji'L:> J:l~ /) C6 l.. .IIJ,.:,,e 0~

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I

A-¥rovM Data or Manual Reference: . ~ _s·5: v -= ff~ o ;.J 'Tr' o ~, - 19c..<_9 - Ci· 7 · ,,'-" ,?4S,H8 :,Joo A.D 'd' - .s r..1- ~ -7 '-/ c. • ;-;,·,s.l-f'ii- ··"Jc-G5~,<1 s,- ;to·-·Jl .. s·1-.20 - ..l..~ - A 1,-1 ~ J...o-:JJ. -6?_

Calibrad ID Number Tools Tool Oescriprion: Too\ Description: Used:

Col l>ue:

Q ty Description Pos PIN Off:

t t a.. 1:;1vtJr ]:l/ - .s- 1 -.I I.

Al V'1r /' .l'J 31 4-~- :5 - -

·J. r. r(. "';i~1 · S - '-1 -I Alo c/1VE -

Parts Conrinuurion I Sheers $ .5 t i ·] I I Op, Check Transforre<l Leak Check Transferred To Work Card No. To Work Card No

Techni<.: ian Sigl ': (ifrcq,nrc~) lnspcctort ~ tu?t4 · S ? / I

Dat.:: ,_ 5·. I I i 11-V· / 5 Date: ,;__4: M,A..<../ ( J" ,

I 'OR \I 41l<J l "<; Rl·V I

COPY i \\'11 11 1·.J - ('IISTOM ER COPY

IDNumlx:r Tool Dcscriprion:

Cal Due:

PIN On: SIN Off

C fl-'\ '.l I ~-S' - :) ~--c. fJ... "\~ I 'f - 5 - 5 (.' R.. ~.2.11..1 - Sp<-(

s C't6 I j 5 ·--

I Panel Closure Transferred To Work Card No.

CJD RII Sign Off:

r Date:

ID Number

Cal Due:

StNOn Ratch No.

"I, "-/ .$6 I 10 -- :::, 1 ")

I 6, ') ~;".)

FJ...'-t - Dl?Y

I S DR Required YesO

CONTINUATION SHEET 6155 24

AVMAX Aircraft SIN Work Order Work Card

I f s '--( '-I ~02. g_s L/OS~ Page of

Additional Work: Retv /VD T \Planned By: _:! :!..L_ S ?-? J

Rectification: PP~n#A Leid LJ ,=~c h v r-n.10 /1 ./2 S-# In 1 :i( A. ~ ~ 1X A-~ J'l A UN;, //) - 7,u, /'J•~ l"- ,11 "T" -r111ft,111+-J-") ll n4/'~//r ;:;1,~JJ AT'nh /' ,,.,1. ,11,dJ/I 'TrJ-1,, n ~ < .u ~ "3or1 A, n ·"r ilA /"1"1.i.?' J < J .-r,,.._ /'J/:. ,11,1/) />L ,:J ,- J. (' J .,.,,r{/ C-14-r'erl, /J,:J,rr.:',.. V' /::J L / / ,r I

P.1'"'1. 11./0• / .2 ~ 4~ / - W . b . ,Un, ~I < - :l? 3

Tool Description: T.D. No. Rll Block Cal. Due:

Mee~~ Date:

Tnw (AV[) Date: /J. S7'1 J.1 , /.J fJ/1. ~ I 5 \ 73

'L7 /#/1/) -._JAY..

Additional Work: 7 ()elV"f/ Ft l',,f. J9·TeA.1~ --(. Planned By: ~ S7? /

Rectification: r D t' IV r I ,= I e d 1v1 14 re r:t , 4 (. t:>"h/er(. ;l.O..lY. ,3 • ~~j A-IV r/ Pl9C~E~ _ 01 , I A I.A.I tJ ei 11A. /314-"- D ,'~ 11. f)t° I/ I II~ ,vd DASI-I 'ir 3o~ I~ D a, '5 '-1 - ~7<.t- I.f.s'~c-' # ...2. 0 .11- n: o l( ~ ,,,uq ... ,,

-

Tool Description: LO. No. RU Block - .. ~ . Cal. Due:

Mech: Date: Inspector: I~ Date: ~~')?/ ,2 ~ - A PR ·I.S ..J1 ~4_~~ 7--S- M (2 \-S-Additional Work: ,o p Co.A, Ac- ~ A- /1"? Planned By: /}//.~ S 7?i ,

-....---'.).

Rectification: /?J k '76 ...,...,..,,yQ ""/IA- r · .12 r/,,,, .A:J. f /? 7~ )~ ~/.) /-' A L1 7f-.:, / ,f' 1.I ,,,,:, A. ~·,j,,,f

, 0,4~;f's,, ~ c o S' ~ '1-,,. c:::;.,- ::; o -2£ TA~ ,

,.___

Tool Description: l.D. No. R.11 Block Cal. Due:

Mech: I Date: a.dr5 S 'J ? I :2. s ~ /Jr-'A( - / _( r nspw (vJr) I 0--:%" ivJ I !§' I 11:~ \ I ,f; ;

11;1 I 11 1.' • 1,1 , •11 I ti + J,11: I ';

'J':' ·'' ;~" ·,

• '.1 ·.:.

·;t. / ' .,

j

j -

PREPARED 8.8.

CHECKED

DATE Jan-98

Av1'13>< Wotk eJEJHl A;:,;:,,oved D~EI !Dr ·, · NC ·: -.,. W/0=--=---=--_-'91..,._:a,t-c~--W/C~,---~

RDS-54-874 SECT

PAGE I

ISSUE ,r2..

The follov.-ing RD provides a permanent repair f, r nacelle lower side panel skin cracking (p/n 85410627 and 85410628) at Xn 131.50 for both fNBD and OUTBD sides of# I and # 2 nacelles.

This repair permits cutting out maximum 2 .0" of panel material at the forward upper comers of the landtng gear door opening, remaining skin and structure are inspected for cracks before an external repair doubler is installed.

This repair is applicable to both# l and # Z nacelles (INBD and OUTBD lower skin panels.}.simultaneously

The details of this procedure are covered by RD8-54-87 4 section 1. page I issue ,r' 2-page 2 issue l page 3 issue .(2.-page 4 issue I page 5 issue 1

RD ISSUE 1.. Title: Permanent repair for crack /"J----- - -,--- - ---+...----------- -4 ::~, L'ATE . I 7-Jan-98 D\- i\1>..~-"{\ damage at fwd upper corners .j)11-------+------+..:,...;..__.;...__,_-+--·---~ I-' DRAWN

of MLG door opening on both 7 1-------,-,,..,..,..-=-# ·- ++-+-------1----- ---.I ~; APPROVED # I and # 2 nacelle (Xn 131.50)

:;; ..... _____ -~J.,J-,~~!!.,,.-,1..-!!!~:..t;k~l,C,,,.,J...--.,{_ ... STRESS

D. _,.

A.

R.

REPORT NUMBER

RDS-54-874

APPLICABlLITY

DHC-8

Series 100 Models IU2/103/106

Series 200 Models 201 /202

Series 300 Models 30 l/3 l l/3 14/3 l 5

\r -1-,:,:; • 1 · ~DL<z

,,.:;; • ··:

lt)<~\\D\:,'}_j R( tiO} ,d"\ ,~ '->\\!.)J VQ()f T\.(:_

5,(. , ,._, 2,$4 I OG:.lS

.06.:l" lhk repair doubler (2024-:TI clad mat'I) Exlernal corners lo he .25" radius min. Form 10 conlour of nacelle.

'·-.;, - -

" ..-·····:-:.

Install 1-<>ff repair packer .032" thk 2024-T] ,clad material in area shown by: j l

\

-- -- -\--_L-

f-..1.l t. ·-J!'. •·· 1c(",·,.: ~

Trim out d11magcd section of lt541062S skin as shown. Use MIN .40" radius on all corners. See General Notes for detailed repair i11s1mc1ions. DO NOT CUT OR DAMAGE INTERNAL DOUBLER 85410625

UP

Lr-uo

THIS REPAIR IS CONSIDERED NULL AND VOID IF ANY INTERNAL STRUCTURE IS DAMAGED.

'!~ n1 .5 ti 11.~.1'1,

< ;· ~ 0 ::s

2 tzj t;, ... a: rt 0 ... =II: ... ::s .. n rt C rt

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//i ;- ii ---------_______ -,,--_______ , -!- Ii

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/

' I 11 .J _,_ l

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I ,. - , ~.06]" lhk repair do:11Jler (2024-TJ .,!au uml'I)

[-! ,, ·, -!- 1, 1

--~- , , · _ii E:-.!crnal corners 10 b.! .23" rn<lius min. form

i - 1--· \ - .._______ , to co111our of 11acelfc. I -I ,7 ..___ - -- . c,_,,, > I .- / -J.::.. -- ---:::::::::::__

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.-~/ r i f ~ 11· -1_- It __ l 1. 'i /_·J,:._,· ,· -r' 1~ -n · <l ct · r 8"4 6.. · '1 I' , rnn 0111 amagc sec-!loa o J W ,.7 sk111

--1

v11,,. 1.0 11 and 854 Hl624 dm1tilcr ·ns shewn. Use MiN

;·,, ~ ;!, Ill 1 · I • A . • ,I

.

.. )i._11,-· -_-t-_--~ . L/~ :I 1'1' 'K Ii :, 1:: ,11· AO" radius OJI nil corr;:::rs. Sec 'Gc11crnl . ,., / - r Noles for dclailcd repair.inscmclions.

- ,=-- -__,,.,,J I , 'I I -:1- . I J11s1all I-off repair packer .04 0" 1!!!<_702-1- . · ~.,. > ~ f' .,f- 1J -K l.?f clad11m1crial i11arc:ishownby:r:_.;:r_d.;1n ·o:g.3

\\ -~--1 ;-f---,f, r~-- 7 ;:: !i 1--6-. _ ,I ,_, ,,, -- lll',1a! i 1-o!T rcp;iir packer ,071" as req'd from ;;;- o

2IJ2-l-T.1 clad 111at'l in area <lcno1ct1 by: c .: ~ ~ ~ a l 1 I

r ~~ ! (

_.j I ' <--1 f ¥ I I 'O

I (.")

i

I i ,'

t--~-- - --j I i ! ' i 1

r • .. _

~ S?l/

PREPARED 8.8.

CHECKED

DATE Jan-98

General notes:

RDS-54-874

SECT 1

PAGE -'

ISSUE

This repair may be carried out on either# 1 or# 2 nacelles (or both) on either the INBD or OUTBD side skin panels (or both) simultaneously

l . Cut out skin damage as shown on pages 2 and 3. Ensure all corner radii are min .40" Do not damage underlying doublers as specified on previous pages outside of cut-out area. Do not damage underlying door edge members.

Ensure all crack damage is removed by damage cut-out. TIDS REP AIR IS CONSIDERED NULL A.-i-m VOID IF ANY UNDERLYING STRUCTURE SUCH AS DOOR EDGE MEMBER IS DM1AGED

fl\ P n - -2 s - t 5 All cut edges are to be smooth and free of nicks. Bare edges are to be touched up with alodine and epoxy primer. After cutting away the skin ensure remairjng structure is free of any damage. Crack inspect the rernaining skin usir.g fluorescent penetrant dye or eddy current(preferred method) to ensure the remaining skin is completely free of cracks.

( __

2. Fab ric~te repair packers and external doublers from 2024-T3 clad material (QQ-A-250/5) All new parts are to be finished with alodine and epoxy primer. Enst.:re a minimum comer radius o( .25" Maintain min .050" gap

-;. 'be.t\vec:; p .ckers and cut-out edges. \

Alotiine ir, accordance with the instructions of the DASH 8 structural i@ 7 /t/1/1 (S' Av[)MAX J '

73

~:J.7',,/iPl~1.54

5 ? ·7 I

ad4~??,S J.J ... r-J./.'Jt.-1.S

repair m2. :· ·.1 :il PSM l-8(2 h· 51-20-1 6.

6\{, D o\~ J)il't L

Eroxy r .,e in accordance with the instructions of the DASH 8 structural r::pair m. ·ual PSM 1-8(2)(3)- ter - 1 -36.

0V.., \c:, (';Me_

Repair e· :;ng fa5tener dimples remaining in the skin underneath the external · air doubler i,, accordance wi th the instructions of the DASH-S ~.tr.;c iur:;;. ::iair manuai ?SM l -S(2)(3 )-3 chapter 51- I 0-2 l page 6.

~ :S") 71 6. Faysea'. a:. ~1ating surfaces with Pro Seal 870( or equivalent sealant in ., ?- /Cf/? ac..:o rdarK wnh DASH-S structural rc:pair manual PSM l-S(2)(3)-3 "" I(~ '5 chapter 5 : ·0-26.

~ S7? I

'A.? ... 141' 1t - 1 5

Fillet se:<i :. ·,:, und ,he edge5 o ft he e:-.:terna.l repair doubler w ith PR14'.?.2-82 or t C],.!i':J.1, -: in accordance wiih the instruct ion:, of che DASH 8 strnctural

. . l:., ,~ ' ' I ~ ( ' 1 )( • ) -. ' · - l ~ 0 .., -. rep::ur mar,,.::1 .)1-, 1 -.., . ·· , .) -J cnapter ) -.) -: . 1!\,\ 1

C)\r.. ~o t I\ s\~ \ \, J( _ :AX

.!AX

, ; .

( :

* * if

! '

1--..

-L. I

PREPARED B.6. RD8-54-~ .

SECT I

PAGE S

ISSUE I

cm:o:i::o

DATE Jan-93-

8. Maintain a minimum of two times the fastener diameter edge distance, unless otherv..i se specified. The edge distance is measured from the center of the fastener hole to the edge of the material and must be maintained on all material through which the fasten~r passes.

9. Functionally test :tv1LG doors to ensi..: re the free operation of the door (ie no hang-up or binding) .

.......

,Rivet codes: 1 ( : I

·.,

Install CR.3214-5 rivets at new locations. (pitch to match adjacent existing fasteners)

Install CR.31 14~5 rivets at cxisti:ig locations. Hole Dia .160"/164", Csk,Dia .242"/.247".

Install N A-S 1097 AD-5 rivets at existing locations. Hole Dia .159".166", Csk Dia .. 23 l "/.236"

{nstall C?(..3214-4 rivets at existing locations. Hole Dia .. 129"/.132" Csk Dia .. 191 "i. I 96"

Refererv.: -= only

PARTS CONTINUATION SHEET 5503

Aircraft Serial No. Work Order No. Work Card No. I/Continuation Sheet . ": " 5.S-c/ I ?rtJ 2 ~ ) 40 5 8' No. I of

PARTS USED Qty Description POS PIN Off P/NOn SIN Off S/NOn Batch No.

I It.. 1T PJ-.,;i,, c- - C 1116 'lf- l'i 2. )(' 171.Y -~ '?/

l1<1T ,or' e_oAT ..__ (l?Osl'7 /')..'-/ 7 6 .f

\ Mt~,;\ - .~C) y7) •. t'i/,,1' ' --- 1)(.,,C,'75

I Me to.I - ;;ioJ 4-r3 - -~ -- ro t; 11 I _,,, c-,1=-~ ,_-c,, ·1

--I

I ··- ~-

··- - ···

·--

·- -

Fom,402 Copy l (White) · Customer Copy 2 (Yellow) - Contro lled

/ ·- -·- - - ·----- --- - ·---·- -

SHIP TO;

KAISER AM CASTLE METALS 4175 ROYAL DRIVE, SUITE 600 ALLIM/NUM KENNESAW, GA 30144

Trentwood Works - Spokane, WA 3 9215 Phone: (800) 367-2586

CERTIFIED TEST REPO SOLo··o ; RT At-.1 CASTLE & CO- SOLD TO

Serial Number 14:20 KENSINGTON RD . 4313444 A\1 mft ,.: V-1~,,:-. SUITE 220

r-.;:pr,· ... :c:~ o .. , Q;l.K BROOK! IL 60523 NC ,t/10---111r:. -

CUSTOM:R PO NUMBER: l WORK PACKAGE: I CUSTOWER PART NUMBER: I SHIP RU tlfLOAO: I GOV'T CONTRACT NJ 23984~ 77DC93 102766/13

MSER:

KAISER C1RDER NO: LINE ITEM:

1

SHIP DATE: rLLOY: 1159084 1 24-0CT-201 3 2024

WEIGHT i;HIPPEO: QUANTITY: I TRUCK B/L #: 6526 LB 2 PCS EST. 2044628

MHU 17254 i 2: LOT 663056AO: 1 pieces; MHU 172 541 3: LOT 663056AO: 1 pieces;

CLAD: I TEMPER:

ALCLAD T3

t RODUCT DESCRIPTION:

HT Coll GAUGE: OIAMET:RfWIOTH: I LENGTH: 0 .0630 IN 48.000 IN 0.000 IN

( 1.6002 W-A) (1219.2MM)

Certified Specifications ocr 2 a ' 201,1

AMS4462 CMMP 019/RevD

TestCode: 1505

AMS-QQ-A-250/5/RevA CMMP 025/RevU

Test Results

lot: 663056.AO Cast 637 Drop 99 Ingot 1

.(~STM EB/B557) (EN 2002-1 J Tens ile: Temper

T3 Dir / # Tests LT / 2 (Min:Maxl

(AS'fM ·E-125-1)---·· - - ·· · ·· - · · Chemistry: SI FE cu Ac:tual(wt%) 0. 10 0 .22 4 .5

SI FE cu 2024 MIN{wt%) 0.00 0.00 3.8 MAX(wto/o) 0.50 . 0;50 4 .9 ·

Liner Alloy : 1230 MIN(wt%) 0.00 0 .00 o.co MAX(w::% ) 0.25 0.30 0.10

MN 0.57

MN

0.30 0.9

0 .00 0.0 5

Ultir:iate KS! (IViPA) 65 .9: 66 .0 (45 4- : 455)

MG CR 1.3 0.01

ALLOY LIMITS

MG CR

1.2 0 .00 1 .B 0 .10

0.00 0 .00 0.05 0.03

Aluminum Remainder

Yield KSI (MPA) 46.4: 46.9 (320: 323)

ZN Tl 0. 12 0.02

zr, Tl

0.00 0 .00 0.25 0 .15

0 .00 o.oc 0 .05 0.03

AST\il 6 209/,C\e\ 1 0

V 0.01

V

0.0 0 0.05

0.00 0 .0 3

Meted in USA

Elongatio;i 3/o 16.4 : 18.:

ZR 0.00 TOT

ZR o rHER

0.00 lACH 0.05 TOT

0 .00 EACH 0.03 TOT

OTHER

0.04

MAX

C.05 0 .15

0.03 ('

~IPTO: <

KAISIEIJ!I FUTURE METALS INC 10401 ST A TE STREET ·ALUMINUM TAMARAC, FL 33321 Trentwood Worlts • Spokane, WA 99215

Phone: (800) 387-2588

SC>LDTO: CERTIFIED TEST REPORT FUTURE METALS INC Serial Number.iw:;,,,, 't,0,1, Caic, PO BOX26450

4256082 /,p;n:-·1ed DJi~· .: r s '--( <( 10401 STATE STREET. A/C ~6 TAMARAC, FL 33321 VJIC

VJ.'(: -----YO

CllSTOMEA PO NUM811!R: !WORK P'ACKAOE: I CUSTOM~ 1'ART NV11181!!1t: I SHIP ltUNLOAD: I OOV'T CONTIIACT NUMSER: 1U1245 102262/5 KAI~ ON>Ult NO: LINe JTeM; l - DAn: I Al.LOY: CLAD: l~R: I ~WWWIION: 1~23398 1 1-MAR-2012 2024 Cl.AD HT Flat Sheet WIEIGHT IHPP'~: QUANTITY:

I BA. NUMBER: QAUO&: I D~= I LBIG'TM: 6H07 LB 292 P~S EST. 2036017 0.0320 IN 48.000 IN 144.000 IN

MHU 1687226: LOT 5780!51A5: 101 pieees; MHU 1567248: LOT 578051Al5: 184 piece LOT 578061A4: 7 pieces;

Certlftec:I Specifications

AMS 4041/RevQ CMMP 019/RevO

TNt c;ocs.: 1505

AMS-OO-A-250/5/RevA CMMP 0215/RevU

T"tReaults

Lot: 678051A5 C.at 584 Drop 63 Ingot 4

(ASTM E8/B557J (EN 2002-1 l Tensile: Temper Cir / ti Tests Ultimate KSI (MPAJ

T3 LT / 2 (Mln:Max) 61.2 : 151 .9 (422: 427)

(ASTM E1251) Chemistry: SI FE cu MN MG CR Actuel 0 .07 o.,a 4.15 0.53 1.4 0.01

Future Metah 111114&1'6

ASTM B 209/Rev10

Mett.d In USA

Yield KSI (MPAI Elongation 'l', 41 .5: 42.3 17.8 : 19.4 (286: 292)

ZN Tl V 0 .09 0 .01 0,01

OlSIOID<rllllJI< AVMAXJACKSONVILLE AddlDO!lal ltlfo Item: 2 CUMmcrP.O. 113977 Qty l SHEET

ZR 0 .00

OTHER TOT 0 .03

Page 1 of 2

Sllil'P"' Number WA55472 Dm 110ct2012

CUSTOMER: AVMAX

,.... DATE: 04/26/2015

AIRCRAFT INFORMATION:

AIRCRAFT TYPE: Dash8-300

~FAA CRS# W2XR853X

~ AEROWELD, INC.

NDTREPORT

AIRCRAFT REGISTRATION NUl\fflER: N387CA

SERIAL NUMBER: 554

NDT EQUIPMENT USED:

--;;J,, P.O. No. 126461

- W.O. No. Al5-273

PENETRANT O MAGNETIC PARTICLE O EDDY CURRENT l:8J ULTRASONIC O RADIOGRAPH 0

THERMOGRAPH O OTHER 0 -----------INSTRUMENT: Olympus Nortec SOOD

INSTRUMENT SERIAL NUMBER: NSOOX1718R010717

NEXT CAL DUE: 08/06/15

DESCRIPTION Ol WORK PERFORMED:

Performed HFEd oi cut-out on #2 nacelle FWD OTBD corner IA W Dash8-300 NDTM part 1 51-00-06 . .,,., - - . .

· ~o cracks indicated.

· -~Work Card: 4058

NAME: Chris Mann SIGNATURE:

NDT Level II

AEROWELO, INC 433 BREESPORT BSAN ANTONIO, TEXAS 78216 Iii PHONE 210-590-7888 tl FAX: 21 0-366-2618

FormAW-1 (6/12)